The aim of the project is the development of a pre-commercial prototype mould with built in continuous structural health monitoring. This will be achieved by carrying out research work appropriate for developing femtosecond laser metal processing techniques to produce smooth walled and depth-controlled grooves on metal parts. In these groves a TiN/Al2O3 composite will be sintered in a few micron thick layer that will work as a wave guide for high frequency pulsing. The measurements will be processed by an FPGA or appropriate dedicated DSP module, to give the user a real time indicator of the structural health of the metal part. If the steel surface gets damaged or is worn down through use, the ceramic grid will crack or become thinner and have increased resistance. Using a number of transducers the surface damage can be quantified and allow for preventive maintenance. The developed technology will be implemented and tested on high precision flanges used in machine construction and on moulds used for injection molding, and hence these will work as proof of concept. The technology could potentially also be used for real time health measurements on dyes for extrusion, in the automotive industry the technology can be applied to driveshaft’s, gears, break pads and a number of other areas where steel surfaces are subjected to continuous friction.